Module Assembly Update Ohio State University and Princeton University are presently preparing facilities for module assembly. Both universities are fabricating parts for the module assembly fixtures. Shipping and testing boxes are presently in an iterative design mode to determine the best and most cost effective way to proceed. Planning for testing and quality control is in progress. Installation procedures are being coordinated by SLAC and Princeton engineers. (information in this document is based on 9x8 double layer tubes)

Shown below is a footprint of the Princeton high bay area where tubes will be received and tested,after assembly the modules will be tested and stored here. Ohio State will have a similar facility.

This shows the Princeton Elementary Particles area where modules will be assembled and put into their testing and shipping boxes. Ohio State will build like assembly fixtures and have a similar set up.

The module assembly fixture is designed to assemble 10 different size modules for a total of 354 modules needed. Both Princeton and Ohio State will have 4 assembly fixtures for production. The fixtures are designed to pivot vertical for removal of the modules in their most rigid orientation. Presently design is done for 9x8 double layer tubes but the fixtures can be adapted to accommodate large single cell modules.

Below is a 3-D rendering of the assembly fixtures.

Below is a 5 module box which will receive 5 cartridge containing first tubes from Italy and then modules for testing and shipment.

Five module box with cartridge boxes inserted. With 5 cartridges inserted the box will weigh approximately 300 pounds.

Proposed design for source scan apparatus. Tubes and then modules will be scanned at Princeton and Ohio State. The source is motor driven on a 4m rail and is moved and pinned by hand to the center of each tube.

View of source holder and shutter

The graphic below represents a study done by Vito Casarriti on the vertical stiffness of modules. The results show that a minimum of 5 tubes is needed for the appropriate handling rigidity. Six tubes per module will be the standard for better utility routing.

Proposed Stiffening Rib A stainless steel rib to be inserted between the tubes that comprise a module will add rigidity to the module in the horizontal position. The module will still need to be handled in the vertical position but the ribs will add needed strength for installation and operation. Holes down the center of the rib do little to degrade the strength of the rib and it allows flow of epoxy from one tube to the next giving a better bond than only stainless to PVC.

Modules will be installed without corner plates or center plates in place but for replacement of a module the center plate must be removed on the horizontal sextants and one of the center plates must be removed on the side sextants corner plates remain installed.

This table is of the barrel layer openings provided by SLAC for RPC design. The sizes in millimeters represent the opening minus 5mm on each side.

This table is the actual production sizes of the barrel RPCs

Installation fixtures that will be used for brass installation and module installation are being drawn up at SLAC. Brass deflection problems are being considered at SLAC and Princeton. Ohio State and Princeton are working on quality control procedures for the tubes and modules at their respective sights. SLAC will also be implementing a quality control plan for the modules when they arrive at on sight.